7.5.5 Identification of Stored Product - External auditor identified storage problem

[Claes Gefvenberg]

Well, it wasn't a documented procedure, or controlled form - more of a shopfloor initiative. I wasn't aware it was happening until the audit. Now the debate is whether to continue to use the form - and train dozens of people to update it, or simply discontinue use.

A shop floor initiative? That in itself, suggests to me that it may be a good idea to keep it (If necessary, in a suitably modified form), because:

• The very point that it has emerged suggests that a need for it exists.
• Approving it will acknowledge your staffs involvement.
• It will pave the way for future cooperation with the staff.
• It may prompt them to come up with new ideas.

You seem to have a dialogue going with the staff already. Keep it going.

/Claes

 

[RoxaneB]

If the form was to be made an official part of the system, I don't see the reason to train dozens of people. The Users of the form are already familiar with how it's used...grandfather them in. Unless, of course, you decide to tweak the process a bit.

Something else to consider that is low cost and relatively low maintenance. When I started with my company, I noticed that our QC Lab used a form of logging location of partly finished product that I absolutely hated! Despised! And made it my personal goal to get rid of...

...but before wiping the existence of this method from the face of the planet, I decided to investigate it. I'm thrilled that I did and I'm continually amazed that such a simple means of tracking locations works! It's called a...

...blackboard.

Yup....a blackboard...complete with chalk.

This blackboard with different colours of chalk record location of our partly finished product out in the yard. Every audit has found it to be up to date. Our QC personnel update it several times a shift as part of their routine. It does match what's in the computer system, but at a glance provides an excellent visual of the status of our yard.

The blackboard and I have come to terms and we get along great now.

And if you're worried about pranksters erasing the board, then you have bigger issues with your organization than forms not being completed.

FYI, we did erase the board once...on April 1. The QC Manager had an absolute fit!!! A Scotsman in a rage....he matched his clan's kilt! But we took a picture of the board prior to erasing it and we were able to put everything back as it was.

 

[Claes Gefvenberg]

FYI, we did erase the board once...on April 1. The QC Manager had an absolute fit!!! A Scotsman in a rage....he matched his clan's kilt! But we took a picture of the board prior to erasing it and we were able to put everything back as it was.

Oooooh, that was naughty....:mg: I hope he didn't have a heart condition or anything. The poor man... With coworkers like that, who needs enemies? Tell me: Did he stage some particularly nasty retaliation?

Ok, Joke apart. That sounds like someone grasped the KISS principle. I like it.

/Claes

 

[Cari Spears]

The blackboard and I have come to terms and we get along great now.

That's cute - lol.

 

[Cari Spears]

A shop floor initiative? That in itself, suggests to me that it may be a good idea to keep it...

Good point, Claes. (as usual )

 

[Kerrym]

If the form was to be made an official part of the system, I don't see the reason to train dozens of people.

...I'm thrilled that I did and I'm continually amazed that such a simple means of tracking locations works! It's called a...

...blackboard.

Yup....a blackboard...complete with chalk.

This blackboard with different colours of chalk record location of our partly finished product out in the yard.

Thanks RC! That's an excellent idea. One of the problems with the current form is that it's computer based - an excel spreadsheet. Using the form is hardly rocket science, but would mean training operators and seasonal staff - all the people moving product in and out of the racks - how to update the form. A board in each of the 2 rack areas might be a better approach, since shift assignments and maintenance requests are already written up on whiteboards in that department. If it's something they're comfortable with, the training may not be a big issue.

 

[RoxaneB]

Did he stage some particularly nasty retaliation?

No, thankfully. Once he realized it was a joke, he calmed down pretty quickly. Although, the QC Technician who had rewrite the entire board wasn't happy with his assigned task.

Thanks RC! That's an excellent idea. One of the problems with the current form is that it's computer based - an excel spreadsheet. Using the form is hardly rocket science, but would mean training operators and seasonal staff - all the people moving product in and out of the racks - how to update the form. A board in each of the 2 rack areas might be a better approach, since shift assignments and maintenance requests are already written up on whiteboards in that department. If it's something they're comfortable with, the training may not be a big issue.

We have an excel spread sheet set-up in our warehouse for finished product and our staff are very diligent about keeping the map up-to-date. Occasionally, there will be some product that isn't where the map says it is, but an investigation usually provides a good explanation (e.g., product moved to access particular product to be shipped, etc.).

Training for staff would be very easy on this process. You document simply that the location of the product is to be (a) entered into the electronic system first and (b) written on the blackboard second. Do not control the "template" of the blackboard.

I say that only because we have a similar set up in our raw materials yard where a whiteboard is used to show pile location. Pile#1, for example, always contains the same raw material. However, Pile#1's location may move around. On Monday, Pile#1 may be in the North-East corner of the yard but by Friday, it may be in a central location.

Either way, develop a system that works for you and is both effective and efficient. The shop floor developed this system on their own initiative - something that really needs to be recognized and praised. What you're trying to do is take it to the proverbial next level, something that they should be included in on, as well.